Ring-shaped cover for portable electronic device

ABSTRACT

An outer cover for an electronic device, such as a portable electronic device, is disclosed. Since portable electronic devices are often portable, they can be damaged, such as scratched, dented, broken, and the like, when transported or used. The outer cover can serve to provide a protective member over part of the housing for the electronic device. The protective member, when placed on the portable electronic device can serve to reduce damage to sides of the portable electronic device. While the outer cover can provide side and/or edge protection, the outer cover need not also provide front or rear protection.

BACKGROUND OF THE INVENTION

Portable electronic devices are commonplace today. Some examples ofportable electronic devices include portable digital assistants,portable media players, mobile telephones, and portable game players.

A conventional portable electronic device includes a housing that formsan external surface of the portable electronic device. The housing oftensupports a display and user input devices. The display can present agraphical user interface to a user of the portable electronic device.The user input devices can include buttons, touchpads, and/or dials thatallow the user to interact with the portable electronic device. Thehousing of the portable electronic device can also include one or moreexternal connection ports. The external connection ports allow theportable electronic device to be connected to a host device (e.g.,personal computer) or other electronic devices (e.g., docking station),so as to exchange data or to charge a battery utilized by the portableelectronic device.

Typically, the exposed surfaces of portable electronic devices arerelatively easily damaged such as by scratches, dents and the like.Covers, skins or cases have been conventionally utilized to provideprotection for the exterior surfaces of portable electronic devices.Accordingly, users can protect their portable electronic devices byplacing covers or skins around their portable electronic devices.Unfortunately, the covers, skins or cases tend to impede use of theportable electronic device. Hence, there is a continuing need forimproved approaches to provide ways to protect portable electronicdevices with minimal hindrance to usage.

SUMMARY

The invention pertains to an outer cover for an electronic device, suchas a portable electronic device. Since portable electronic devices areoften portable, they can be damaged, such as scratched, dented, broken,and the like, when transported or used. The outer cover can serve toprovide a protective member over part of the housing for the electronicdevice. The protective member, when placed on the portable electronicdevice can serve to reduce damage to sides of the portable electronicdevice. While the outer cover can provide side and/or edge protection,the outer cover need not also provide front or rear protection. Theinvention is particularly well suited for handheld electronic devices.

In one embodiment, the outer cover can be formed from material ofdifferent harnesses. For example, a middle portion can be formed from astiff plastic material, while one or more outer portions can be formedfrom an elastomer that has more compliance capability that the stiffplastic material. The outer cover with the different materials can beformed through injection molding. In one embodiment, the injectionmolding can use a double-shot injection molding to form the outer cover.The first shot of injecting molding being for the stiff plastic materialand the second shot being for the compliant elastomer material. One ormore alignment features can be formed in the middle portion tofacilitate subsequent alignment for formation of the one or more outerportions.

In one embodiment, the outer cover can include an elastomer section thatfacilitates slight expansion of the outer cover. The slight expansionfacilitates attachment and removal of the outer cover to an electronicdevice, while still being able to be securely attached to the electronicdevice when acting as an outer cover therefor.

In one embodiment, the outer cover can include one or more openings thatfacilitate usage of an electronic device with the outer cover in place.For example, the one or more opening in the outer cover can correspondto a connector location (e.g., input/output connector, audio jack,speaker openings, etc.) of the electronic device. These openings allowaccess to connector(s) of the electronic device through the outer cover.As another example, the one or more openings can support actuators thatare provided with the outer cover. Typically, the actuators arepositioned within the outer cover such that their placement correspondsto the location of switches (e.g., buttons) on the electronic device.

The invention may be implemented in numerous ways, including, but notlimited to, a system, device, apparatus or method. Exemplary embodimentsof the invention are discussed below.

As a protective cover for a portable electronic device, one embodimentcan, for example, include at least a middle ring having at least oneopening for access to an input component of the portable electronicdevice, a top ring integral with or attached to a top portion of themiddle ring, and a bottom ring integral with or attached to a bottomportion of the middle ring.

As a ring-shape cover having an opening configured to receive a portableelectronic device, one embodiment can, for example, include at least acenter band formed of a first material, a top band formed of a secondmaterial and integral with a top portion of the center band, and abottom band formed of the second material and integral with a bottomportion of the center band.

As a method for forming a cover for a portable electronic device, oneembodiment can, for example, operate to form an inner band structureusing a first moldable material. Once the inner band structure isformed, at least one outer band structure using a second moldablematerial can be formed and bonded to the inner band structure.

As a method for forming a cover for a portable electronic device,another embodiment can, for example, configure an injection moldingapparatus for a first molding operation. Once configured, the firstmolding operation can be performed using a first moldable material toform a middle band structure. Afterwards, the injection moldingapparatus can be configured for a second molding operation. The secondmolding operation can then be performed using a second moldable materialto form a top band structure and/or a bottom band structure onto themiddle band structure that has already formed.

As a kit, one embodiment can, for example, include at least a portableelectronic device, and a protective cover for the portable electronicdevice. The protective cover can include at least a middle ring havingat least one opening for access to an input component of the portableelectronic device, a top ring integral with or attached to a top portionof the middle ring, and a bottom ring integral with or attached to abottom portion of the middle ring.

As an edge cover for an electronic device, one embodiment can, forexample, include at least a removable peripheral member that surroundsthe peripheral sides of an electronic device in order to protectperipheral sides of the electronic device. The removable peripheralmember can include a middle band and an upper and lower band disposedabove and below the middle band. The middle band primarily can have afirst material characteristic, and the upper and lower bands can have asecond material characteristic that is different from the first materialcharacteristic.

As an edge cover for an electronic device, another embodiment can, forexample, include at least a removable peripheral member that surroundsperipheral sides of an electronic device in order to protect theperipheral sides of the electronic device. The peripheral member canhave an opening extending through the peripheral member and configuredto receive the electronic device. The peripheral member can form a bandconfigured to fit around the peripheral sides of the electronic device.

As an expandable edge cover for an electronic device, one embodimentcan, for example, include at least a first portion in the form of amiddle band having a cut out section thereby making it non-continuous,and a second portion integrally formed with the first portion. Thesecond portion can fill the cut out section and form a continuous upperand lower band. The second portion can be formed from a compliantmaterial thereby allowing the edge cover to flex when the electronicdevice is inserted therein.

Various aspects and advantages of the invention will become apparentfrom the following detailed description taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be readily understood by the following detaileddescription in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective diagram of an outer cover for an electronicdevice according to one embodiment.

FIG. 2A is a side sectional view of the outer cover illustrated in FIG.1, according to one embodiment.

FIG. 2B is a side sectional view of an outer cover according to analternative embodiment.

FIG. 3A is a perspective view of an exemplary portable electronic devicein accordance with one embodiment.

FIG. 3B is a perspective view of an outer cover provided on the portableelectronic device illustrated in FIG. 3A.

FIG. 3C is a cross-sectional view of the outer cover together with theelectronic device as illustrated in FIG. 3B in accordance with oneembodiment.

FIG. 4 is a perspective diagram of an outer cover for an electronicdevice according to another embodiment.

FIG. 5 is a side sectional view of the outer cover illustrated in FIG.4, according to one embodiment.

FIGS. 6A-6D are side sectional views of other portions of the outercover illustrated in FIG. 4, according to one embodiment.

FIG. 7 is a perspective view of an outer cover provided on the portableelectronic device illustrated in FIG. 3A.

FIG. 8 is an exploded assembly diagram illustrating assembly of a poweractuator and a volume actuation for an outer cover according to oneembodiment.

FIG. 9 is an exploded assembly diagram for an outer cover according toone embodiment.

FIG. 10 is a perspective diagram of an outer cover for an electronicdevice according to another embodiment.

FIG. 11 is a flow diagram of an outer cover formation process accordingto one embodiment.

FIG. 12 is a flow diagram of a molding process according to oneembodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The invention pertains to an outer cover for an electronic device, suchas a portable electronic device. Since portable electronic devices areoften portable, they can be damaged, such as scratched, dented, broken,and the like, when transported or used. The outer cover can serve toprovide a protective member over part of the housing for the electronicdevice. The protective member, when placed on the portable electronicdevice can serve to reduce damage to sides of the portable electronicdevice. While the outer cover can provide side and/or edge protection,the outer cover need not also provide front or rear protection.

In one embodiment, the outer cover can be formed from material ofdifferent harnesses. For example, a middle portion can be formed from astiff plastic material, while one or more outer portions can be formedfrom an elastomer that has more compliance capability that the stiffplastic material. The outer cover with the different materials can beformed through injection molding. In one embodiment, the injectionmolding can use a double-shot injection molding to form the outer cover.One or more alignment features can be formed in the middle portion tofacilitate subsequent alignment for formation of the one or more outerportions.

In one embodiment, the outer cover can include an elastomer section thatfacilitates slight expansion of the outer cover. The slight expansionfacilitates attachment and removal of the outer cover to an electronicdevice, while still being able to be securely attached to the electronicdevice when acting as an outer cover therefor.

In one embodiment, the outer cover can include one or more openings thatfacilitate usage of the electronic device with the outer cover in place.For example, the one or more opening in the outer cover can correspondto a connector location (e.g., input/output connector, audio jack,speaker openings, etc.) of the electronic device. These openings allowaccess to connector(s) of the electronic device through the outer cover.As another example, the one or more openings can support actuators thatare provided with the outer cover. Typically, the actuators arepositioned within the outer cover such that their placement correspondsto the location of switches (e.g., buttons) on the electronic device.

The invention is particularly well suited for portable electronicdevices, and more particularly handheld electronic devices. Examples ofportable electronic devices can include laptops, tablet computers,portable media players, mobile phones, mobile GPS units, remotecontrols, personal digital assistant (PDAs), and the like.

Embodiments of the invention are discussed below with reference to FIGS.1-12. However, those skilled in the art will readily appreciate that thedetailed description given herein with respect to these figures is forexplanatory purposes as the invention extends beyond these limitedembodiments. The illustrations provided in these figures are notnecessarily drawn to scale; instead, the illustrations are presented ina manner to facilitate presentation.

FIG. 1 is a perspective diagram of an outer cover 100 for an electronicdevice according to one embodiment. The outer cover 100 serves toprotect at least a portion of a housing of the electronic device.Typically, the electronic device is a portable device, i.e., a portableelectronic device.

The outer cover 100 is designed to surround sides of the electronicdevice, while leaving primary front and rear sides open (or uncovered).As shown in FIG. 1, the outer cover 100 can include a middle band 102that can have a ring shape configured to extend around the sides of theelectronic device. The outer cover 100 can also includes a top band 104that is bound to the middle band 102. The top band 104 can also have aring shape that is configured to extend around the sides of theelectronic device. The outer cover 100 can also include a bottom band106 that is bound to the middle band 102 which forms a ring that isconfigured to extend around the sides of the electronic device.

Since the outer cover 100 is designed to surround the sides of theelectronic device while leaving the primary front and rear sides open,the outer cover 100 includes an opening 108 that extends through theeach of the middle band 102, the top band 104 and the bottom band 106.When the outer cover 100 is to be utilized, the electronic device can beplaced within the opening 108 of the outer cover 100 and removablysecured (e.g., frictional fit) to the outer cover 100. In oneembodiment, the electronic device can be inserted into the opening 108from either the primary front side or the primary rear side.

As further discussed in detail below, the materials utilized for themiddle band 102, the top band 104 and the bottom band 106 can varydepending upon implementation. For example, the middle band 102 can beformed from a plastic that provides a relatively strong and rigidstructure for the outer cover 100. The top band 104 and the bottom band106 can be formed from an elastomer that offers less rigidity and morecompliance than does the middle band 102. For example, the middle band102 can be formed from a plastic, such as Acrylonitrile butadienestyrene (ABS) plastic or polycarbonate. For example, the top band 104and the bottom band 106 can be formed from a thermoplastic, such asThermoplastic Vulcanizate (TPV) or Thermoplastic Silicone Vulcanizate(TPSiV). A specific example of a suitable material for the top band 104and the bottom band 106 is TPSiV 3515 60A.

FIG. 2A is a side sectional view of the outer cover 100 illustrated inFIG. 1, according to one embodiment. The side sectional view indicatesthe top band 104 affixed to the top surface of the middle band 102, andthe bottom band 106 affixed to the bottom surface of the middle band102. In this embodiment, the middle band 102, the top band 104 and thebottom band 106 can each be formed of a different material. Typically,in one embodiment, as noted above, the material for the top band 104 andthe bottom band 106 are the same but nevertheless differ from thematerial for the middle band 102. For example, a multi-mold moldingprocess can be used to form the outer cover 100.

Further in the outer cover 100 shown in FIG. 2A, the outer edges of thetop band 104 can be referred to as being flared out or having flanges.Since the top band 104 and the bottom band 1006 are compliant, theflanges are compliant. These flanges can serve to cover (and thusprotect) front and rear face edges of the electronic device. FIG. 3discussed below illustrates front and rear face edges of an electronicdevice being protected by outer portions (e.g., flanges) of an outercover.

FIG. 2B is a side sectional view of an outer cover 100′ illustrated inFIG. 1, according to an alternative embodiment. The side sectional viewindicates a top band 104′ affixed to the top surface of a middle band102′, and a bottom band 106′ affixed to the bottom surface of the middleband 102′. In this embodiment, the middle band 102′, the top band 104′and the bottom band 106′ are all formed from the same material. Hence,in this alternative embodiment, the outer cover 100′ can be formed froma single material. In such case, the assembly for the outer cover neednot form separate members that are then attached to one another.Instead, the outer cover can be formed as a single piece (i.e., aunitary structure). For example, a single mold molding process can beused to form the outer cover 100′.

FIG. 3A is a perspective view of an exemplary portable electronic devicein accordance with one embodiment. Outer periphery member 302 cansurround the periphery of electronic device 300 to form some or all ofthe outer-most side surfaces (e.g., surfaces 304, 306, 308 and 310) ofthe electronic device. Outer periphery member 302 can have any suitableshape, including for example one or more elements that can be combinedto form a ring. More generally, as examples, the outer periphery member302 can have a substantially rectangular shape (e.g., having straight orrounded edges or corners), a circular shape, an oval shape, a polygonalshape, or any other closed shape that can define a volume.

In some embodiments, outer periphery member 302 can include one or moreopenings, knobs, extensions, flanges, chamfers, or other features forreceiving components or elements of the device. The features of outerperiphery member 302 can extend from any surface of the outer peripherymember, including for example from internal surfaces (e.g., to retaininternal components or component layers), or from external surfaces. Asone example, outer periphery member 302 can include connector opening312 (e.g., for a 30-pin connector) for receiving a connector. Outerperiphery member 302 can include openings 314 and 316 for providingaudio to a user (e.g., an opening for audio output from an internalspeaker), or receiving audio from a user (e.g., an opening for aninternal microphone). Outer periphery member 302 can instead or inaddition include openings for an audio connector, a power supplyconnector, or other features for retaining and enabling a power switch,a volume control switch or a ring silencing switch. As an example, theswitches can be implemented as buttons.

The various features of outer periphery member 302 can be constructedusing any suitable approach and at any suitable time. In someembodiments, the features can be constructed as part of a process thatcreates outer periphery member 302 from a single piece of material thatis manufactures into the final shape of outer periphery member 302(e.g., using a machining process). In some embodiments, several piecesof material can instead or in addition be shaped individually andcombined into outer periphery member 302. Outer periphery member 302 canbe constructed from any suitable material, including for example a metal(e.g., steel or aluminum), plastic (e.g. polyurethane, polyethylene orpolycarbonate), composite material, or any combination thereof. In someembodiments, outer periphery member 302 can be constructed from thecombination of several materials.

Electronic device 300 can include first cover assembly 318 and backcover assembly 320 providing the back and front surfaces of theelectronic device, respectively. Each cover assembly 318 and 320 can becoupled to outer periphery member 302 using any suitable approach,including for example using an adhesive, tape, mechanical fastener,hooks, screws, tabs, or combinations thereof. In some embodiments, oneor both of cover assemblies 318 and 320 can be removable, for examplefor servicing or replacing electronic device components (e.g., abattery). In some embodiments, cover assemblies 318 and 320 can includeseveral distinct parts, including for example a fixed part and aremovable part. The inner surfaces of front cover assembly 318 and backcover assembly 320 can include any suitable feature, including forexample one or more ridges, hooks, tabs, extensions, or any combinationthereof for retaining the covers or ensuring proper alignment of thecovers. The features of cover assemblies 318 and 320 can interact withcorresponding features of outer periphery member 302) or othercomponents of the electronic device to ensure proper placement of thecovers. Back cover assembly 320 and front cover assembly 318 can bepositioned in any suitable manner relative to outer periphery member302.

Returning to electronic device 300, back cover assembly 320 and frontcover assembly 318 can be constructed from any suitable material orcombination of materials. In some embodiments, each of cover assemblies318 and 320 can be constructed by combining several distinct components.For example, one or both cover assemblies 318 and 320 can include atransparent or translucent plate (e.g., a rectangular plate of glass).As another example, one or both cover assemblies can include a base orsupport structure constructed from one or more of a metal (e.g.,aluminum) or plastic onto which a transparent component can beassembled. The transparent component can be assembled using any suitableapproach, including for example such that one or more electronic devicecomponents can be visible through the transparent component (e.g.,display circuitry), or can receive signals or detect a user'senvironment through the transparent component (e.g., sensors).Alternatively, one or more portions of the transparent plate can berendered opaque (e.g., using an ink, or by placing a support structurebehind the transparent plate) such that the transparent plate can alsoserve as a cosmetic purpose. The different components of each coverassembly 318 and 320 can be assembled using any suitable approach,including for example using one or more of an adhesive, fastener, tape,interlocking components, overmolding or manufacturing process, or anycombination of these.

Front cover assembly 318 can include support structure 322 on whichglass plate 324 can be assembled. Support structure 322 can include oneor more openings, including an opening through which display 326 can beprovided. In some embodiments, support structure 324 and glass plate 326can include openings for device components, such as button opening 328and receiver opening 330. The size and shape of the openings 328 and 330can be selected using any suitable approach, including for example basedon the size and shape of the device components placed in or underneaththe openings (e.g., opening 328 can determined by the size of thebutton, while opening 330 can be determine from the size of thereceiver, and acoustic considerations for providing sufficient audio toa user).

In some embodiments, front cover assembly 318 can support or enable oneor more interfaces by which a user can use the electronic device. Forexample, front cover assembly 318 can support a touch interface (e.g., atouch pad or a touch screen) for controlling electronic device processesand operations. As another example, front cover assembly 318 can includeone or more buttons or sensors (described above) for interacting withthe device. In some cases, buttons, switches or other interface elementscan be instead or in addition incorporated in outer periphery member 302or back cover assembly 320. Electronic device 300 can include any othersuitable interface for interacting with a user, including for exampledisplay circuitry, a projector, audio output circuitry (e.g., speakersor a an audio port), a haptic interface (e.g., a motor for creatingvibrations, or a power source for providing an electrical stimulus), orcombinations of these.

In one embodiment, electronic device 300 can also provide back coverassembly 320 in a similar as front cover assembly 318. Back coverassembly 320 can include support structure 332 on which glass plate 334can be assembled. Support structure 332 may or may not need openings fordevice components. Although back cover assembly 320 can, like frontcover assembly 318, support or enable one or more interfaces by which auser can use the electronic device, back cover assembly 320 need notsupport any interfaces.

FIG. 3B is a perspective view of an outer cover 350 provided on theportable electronic device 300 illustrated in FIG. 3A. The outer cover350 can, for example, be similar to the outer cover 100 illustrated inFIG. 1. As shown in FIG. 3B, when the portable electronic device 300 isinserted into the outer cover 350, sides of the portable electronicdevice 300 are protected by the corresponding sides of the outer cover350. The front and rear surfaces of the portable electronic device 300remain exposed and are not covered. However, the front and rear surfacesof the portable electronic device 300 can be partly protected at theedges. Here, the outer cover 300 does provide covering for the edges ofthe front and rear surfaces and is able to provide some protection. Forexample as shown in FIG. 3B, the outer cover 350 include a front surfaceedge cover 352 that extends around the periphery of the outer cover 350.

FIG. 3C is a cross-sectional view of the outer cover 350 together withthe electronic device 300 as illustrated in FIG. 3B, in accordance withone embodiment. Internal to the outer cover are multiple electricalcomponents 336 that are typically secured to a supporting plate 338. Thesupporting plate 338 can be secured to or integral with the outerperiphery member 302. The sides (as well as the edges) of the electronicdevice 300 are being protected by the outer cover 350.

FIG. 4 is a perspective diagram of an outer cover 400 for an electronicdevice according to another embodiment. The outer cover 400 serves toprotect at least a portion of a housing of the electronic device.Typically, the electronic device is a portable device, i.e., a portableelectronic device.

The outer cover 400 is designed to surround sides of the electronicdevice, while leaving primary front and rear sides open (or uncovered).As shown in FIG. 4, the outer cover 400 can include a middle band 402that has a ring shape configured to extend around the sides of theelectronic device. The outer cover 400 can also includes a top band 404that is bound to the middle band 402. The top band 404 can also have aring shape that is configured to extend around the sides of theelectronic device. The outer cover 400 can also include a bottom band406 that is bound to the middle band 402 which forms a ring that isconfigured to extend around the sides of the electronic device.

Since the outer cover 400 is designed to surround the sides of theelectronic device while leaving the primary front and rear sides open,the outer cover 400 includes an opening 408 that extends through theeach of the middle band 402, the top band 404 and the bottom band 406.When the outer cover 400 is to be utilized, the electronic device can beplaced within the opening 408 of the outer cover 400 and is removablysecured (e.g., frictional fit) to the outer cover 400. In oneembodiment, the electronic device can be inserted into the opening 408from either the primary front side or the primary rear side.

The materials utilized for the middle band 402, the top band 404 and thebottom band 406 can vary depending upon implementation. For example, themiddle band 402 can be formed from a plastic that provides a relativelystrong and rigid structure for the outer cover 400. For example, themiddle band 102 can be formed from a plastic, such as Acrylonitrilebutadiene styrene (ABS) plastic or polycarbonate. The top band 404 andthe bottom band 406 can be formed from an elastomer that offers lessrigidity and more compliance than does the middle band 402. For example,the top band 404 and the bottom band 406 can be formed from athermoplastic, such as Thermoplastic Vulcanizate (TPV) or ThermoplasticSilicone Vulcanizate (TPSiV). A specific example of a suitable materialfor the top band 404 and the bottom band 406 is TPSiV 3515 60A.

In addition, to assist with alignment of the top band 404 and the bottomband 406 with the middle band 402 during formation of the outer cover400, a least a portion of the inner surface of the middle band 402 caninclude an alignment groove 410. In the embodiment illustrated in FIG.4, the alignment groove 410 extends along a pair of opposing sides. Inone embodiment, during formation of the outer cover 400, the middle band402 is first molded in an injection molding apparatus, and then the topband 404 and the bottom band 406 are formed in the injection moldingapparatus. The alignment grooves 410 can be use to maintain alignment ofthe middle band 402 once it is formed. As a result, the top band 404 andthe bottom band 406 are able to be formed such that they are preciselyaligned with the middle band 402. More generally, the outer cover 400can include one or more alignment features to assist with it formation.The alignment features can be not only grooves but also protrusions,detents, ribs, ridges and the like.

The sides of the outer cover 400 can include various opening oractuators so that a user is still able to access, control or interactwith the buttons, connectors, ports and controls for the electronicdevice being protected (i.e., covered) by the outer cover 400. In theembodiment shown in FIG. 4, the outer cover 400 includes a power buttonopening with a power cap 412 inserted therein, an indicator lightopening 414, an audio jack opening 416, a ring/silent opening 418,volume control openings with volume caps 420 a and 420 b insertedtherein, an input/output connector opening 422, and audio port openings424 a and 424 b.

By way of the power cap 412, the user can power on and off theelectronic device being protected. The power cap 412 can be arranged todepress a power button on the electronic device. The indicator lightopening 414 allows light from an indicator light from the electronicdevice to pass through the indicator light opening 414 so as to bevisible to the user. The audio jack opening 416 provides an opening sothat an audio jack of the electronic device can be accessed. Thering/silent opening 418 provides an opening so that a ringer/silentbutton of the electronic device can be accessed. The volume caps 420 aand 420 b enable the user of the electronic device to control the volume(up or down control). The volume cap 420 a can be arranged to depressvolume up button on the electronic device, and the volume cap 420 b canbe arranged to depress volume down button on the electronic device. Theinput/output connector opening 422 provides an opening so that aninput/output connector can be accessed. The audio port openings 424 aand 424 b provide openings through which audio sound can be output(e.g., speaker output) from within the electronic device or input (e.g.,microphone input) to within the electronic device.

It should be understood that the various openings or actuators of theouter cover 400 illustrated in FIG. 4 represents one embodiment thatsupports a configuration of a particular embodiment. In otherembodiments, the number, size, placement and configuration of thebuttons, connectors, ports and/or controls for an electronic devicebeing protected (i.e., covered) by an outer cover can vary widely.

FIG. 5 is a side sectional view of the outer cover 400 illustrated inFIG. 4, according to one embodiment. The side sectional view indicatesthe top band 404 affixed to the top surface of the middle band 402, andthe bottom band 406 affixed to the bottom surface of the middle band402. In this embodiment, the middle band 402, the top band 404 and thebottom band 406 can each be formed of a different material. Typically,as noted above, the material for the top band 404 and the bottom band406 are the same but different that the material for the middle band102. Additionally, to assist with the attachment or bonding of the topband 404 to the top surface of the middle band 402, attachment features426 can be provided (e.g., integral with one or both of the surfaces) atthe interface between the top surface of the middle band 402 and thecorresponding surface of the top band 404. The number, shape andplacement of the attachment features 426 can vary depending onimplementation. Still further, to assist with the attachment or bondingof the bottom band 406 to the bottom surface of the middle band 402,attachment features 428 can be provided (e.g., integral with one or bothof the surfaces) at the interface between the bottom surface of themiddle band 402 and the corresponding surface of the bottom band 406.The number, shape and placement of the attachment features 428 can varydepending on implementation. The middle band 402 can also include atleast one alignment groove 410. The at least one alignment groove 410can assist with the forming the outer cover 400.

FIGS. 6A-6D are side sectional views of other portions of the outercover 400 illustrated in FIG. 4, according to one embodiment. FIG. 6Aillustrates a side section view at the portion of the side having thepower cap 412. To support the power cap 412 and its operation, a powerbase 600 and a power label 602 can be assembled behind the power cap412. FIG. 6B illustrates a side section view at the portion of the sidehaving the volume cap 420 a. To support the volume cap 420 a and itsoperation, a volume base 604 and a volume label 606 can be assembledbehind the volume cap 420 a. FIG. 6C illustrates a side section view atthe portion of the side having the audio jack opening 416. FIG. 6Dillustrates a side section view at the portion of the side having theinput/output connector opening 422.

FIG. 7 is a perspective view of an outer cover 400 provided on theportable electronic device 300 illustrated in FIG. 3A. The outer cover350 can, for example, be similar to the outer cover 400 illustrated inFIG. 4. As shown in FIG. 7, when the portable electronic device 300 isinserted into the outer cover 400, sides of the portable electronicdevice 300 are protected by the corresponding sides of the outer cover400. The front and rear surfaces of the portable electronic device 300remain exposed and are not covered. However, the front and rear surfacesof the portable electronic device 300 can be partly protected at theedges. Here, the outer cover 300 does provide covering for the edges ofthe front and rear surfaces and is able to provide some protection. Forexample as shown in FIG. 3B, the outer cover 400 include a front surfaceedge cover 402 that extends around the periphery of the outer cover 400.Also, as shown in FIG. 7, the bottom side and thus the input/outputconnector opening 422 and the audio port openings 424 a and 424 b in theouter cover 400 are visible and aligned with the corresponding openingsof the portable electronic device 300.

FIG. 8 is an exploded assembly diagram illustrating assembly of a poweractuator and a volume actuation for an outer cover according to oneembodiment. The outer cover 800 shown in FIG. 8 is the same as the outercover 400 illustrated in FIG. 4, though the power actuator and volumeactuation are shown as assemblies. For the power actuator, the outercover 800 includes an opening 802 for receiving a power cap 804. On theinside of the outer cover 800, there is a base plate 806 and a label808. The base plate 806 can be metal (e.g., stainless steel) and thelabel 808 can be plastic (e.g., Polyethylene terephthalate (PET)). Forthe volume actuator, the outer cover 800 includes a first openings 810that receives a first power cap 812, and a second opening 814 thatreceives a second power cap 816. On the inside of the outer cover 800,there is a base plate 818 and a label 820. The base plate 818 can bemetal (e.g., stainless steel) and the label 820 can be plastic (e.g.,Polyethylene terephthalate (PET)).

FIG. 9 is an exploded assembly diagram for an outer cover 900 accordingto one embodiment. The outer cover 900 can be formed from a middle bandstructure 902 having a top surface 904 and a bottom surface 906. Themiddle band structure 902 provides an opening 908 around which themiddle band 902 extends.

The outer cover 902 can also include a top band structure 910. The topband structure 910 includes a bottom surface 912. The top band structure910 provides an opening 914 around which the top band structure 910extends. The assembly for the outer cover 900 can include attachment ofthe top band structure 910 to the middle band structure 902. Theattachment can use chemical bonding, adhesive or mechanical structuresto mechanically couple the top band structure 910 to the middle bandstructure 902. When the top band structure 910 is attached or bonded tothe middle band structure 902, the bottom surface 912 of the top bandstructure 910 can be placed adjacent to the top surface 904 of themiddle band structure 902 and secured thereto. Additionally, when thetop band structure 910 is attached to the middle band structure 902, theopening 914 within the top band structure 910 is substantially alignedwith the opening 908 within the middle band structure 902.

The outer cover 902 can also include a bottom band structure 916. Thebottom band structure 916 includes a top surface 918. The bottom bandstructure 916 provides an opening 920 around which the bottom bandstructure 916 extends. The assembly for the outer cover 900 can includeattachment of the bottom band structure 916 to the middle band structure902. The attachment can use chemical bonding, adhesive or mechanicalstructures to mechanically couple the bottom band structure 916 to themiddle band structure 902. When bottom top band structure 916 isattached or bonded to the middle band structure 902, the top surface 918of the bottom band structure 916 can be placed adjacent to the bottomsurface 906 of the middle band structure 902 and secured thereto.Additionally, when the bottom band structure 916 is attached to themiddle band structure 902, the opening 920 within the bottom bandstructure 916 is substantially aligned with the opening 908 within themiddle band structure 902.

In the embodiment illustrated in FIG. 9, the outer cover 900 is formedfrom the middle band member 902, the top band member 910 and the bottomband member 916. These members 902, 910 and 916 are attached together tofor the outer cover 900. Since these members 902, 910 and 916 areseparate structures that are assembled together, they can be formed fromsame or different materials.

In an alternative embodiment, an outer cover can be form from a singlematerial. In such case, the assembly for the outer cover need not formseparate members that are then secured to one another (as, for example,the case with FIG. 9). Instead, the outer cover can be formed as asingle piece (i.e., a unitary structure).

FIG. 10 is a perspective diagram of an outer cover 1000 for anelectronic device according to another embodiment. The outer cover 1000is generally similar to the outer cover 400 illustrated in FIG. 4.However, the outer cover 1000 forms a section 1002 (or portion) withinthe middle band 402′ with a compliant material, such as an elastomer.The section 1002 can also be referred to as a compliant section. Thecompliant material can, for example, be the same material as the topband 404′ and the bottom band 406′. In one implementation, the top band404′, the bottom band 406′ and the section 1002 can all be formedtogether, such as in a common molding process. Typically, the thickness(i.e., height) of the middle band 402′ is greater than the thickness ofthe top band 404′ and the bottom band 406′.

The outer cover 1000 can serve to protect at least a portion of ahousing of the electronic device. Typically, the electronic device is aportable device, i.e., a portable electronic device. By providing theouter cover 1000 with the section 1002 of compliant material, the middleband 402′ is able to temporarily expand so that the electronic devicecan be fit within the opening 409 of the outer cover 1000. Since themiddle band 402′ is otherwise a rigid structure for protection of theelectronic device, the provisioning of the section 1002 of compliantmaterial allows better product usage as well as reliability. Forexample, the middle band 402′ may be primarily formed from a plastic,such as Acrylonitrile butadiene styrene (ABS) plastic or polycarbonate,and the section 1002 can be formed of a thermoplastic, such asThermoplastic Vulcanizate (TPV) or Thermoplastic Silicone Vulcanizate(TPSiV).

Although the middle band 402′ can be primarily rigid, the presence ofthe section 1002 also the middle band 402′ and thus the outer cover 1000to expand. The width of the section 1002 impacts the degree of expansionavailable and thus the expandability of the outer cover 1000 can bemodified by altering the width of the section 1002. For example, in someembodiments, the width of the section 1002 is less than a quarter of thewidth of the outer cover 1000 (i.e., width of the side including thesection 1002).

Although the section 1002 providing the compliant section of the middleband 402′ can be placed anywhere, in the embodiment shown in FIG. 10,the section 1002 is proximate to a corner of the outer cover 1000 andalso include one or more opening therein 414 and 416 which can impactthe degree to which the middle band 402′ can expand. The opening 414 and416 in the outer cover 100 can allow access (e.g., visual or physical)to the electronic device.

In one embodiment, from a materials perspective, the section 1002 in themiddle band 402′ renders the middle band 402′ non-continuous as to itsrigid material characteristic.

Various techniques may be used to form the desired shape/configurationof an outer cover including for example molding or casting techniques.Various molding techniques include compression molding, transfermolding, injection molding, and the like. Some techniques that may beuseful to integrate electronics into the molded part include insertmolding and/or double shot injection molding.

FIG. 11 is a flow diagram of an outer cover formation process 1100according to one embodiment. The outer cover formation process 1000 canbe performed to form an outer cover, such as the outer cover 100illustrated in FIG. 1 or the outer cover 400 illustrated in FIG. 4.

The outer cover formation process 1100 can form 1102 an inner bandstructure using a first material. Then, an outer band structure can beformed 1104 using a second material. If there is a cut-out section (orcompliant section) to be provided within an inner band, then the cut-outsection can also be formed using the second material. After the innerband structure and the outer band structure had be formed 1102 and 1104,the outer band structure can be bonded 1106 to the inner band structure.Following the block 1106, the outer cover formation process 1100 canend.

However, it should be understood that the outer cover may furtherinclude an additional outer band. If an additional outer band isprovided, the additional outer band can be bonded to an opposing surfaceof the inner band structure. For example, the initial outer bandstructure can be bonded to a top side of the inner band structure, andthe additional outer band structure can be bonded to the bottom side ofthe inner band structure.

FIG. 12 is a flow diagram of a molding process 1200 according to oneembodiment of the invention. The molding process 1200 operates toproduce an outer cover. For example, the outer cover being produced bythe molding process 1200 can pertain to the outer cover 100 illustratedin FIG. 1 or the outer cover 400 illustrated in FIG. 4.

The molding process 1200 initially configures 1202 an injection moldingapparatus for a first molding operation. Typically, during theconfiguration 1202, one or more molding plates are placed within theinjection molding apparatus to provide a mold for a first portion of theouter cover being formed. After the injection molding apparatus has beenconfigured 1202, the first molding operation can be performed 1204 usinga first moldable material to form a middle band structure for the outercover.

Next, the injection molding apparatus can be configured 1206 for asecond molding operation. Here, configuration of the injection moldingapparatus for the second molding operation can involve placing one moredifferent plates within the injection molding apparatus to form a secondportion of the outer cover being formed. Thereafter, the second moldingoperation can be performed 1208 using a second moldable material to forma top band structure and/or a bottom band structure onto the middle bandstructure. Here, in one implementation, the middle band structure beingformed by the second molding operation can remain within the injectionmolding apparatus during formation of the top band structure and/or thebottom band structure. By doing so, the top band structure and/or thebottom band structure can be molded, and thus bonded to the middle bandstructure, with accurate alignment. By bonding at the top band structureand/or the bottom band structure onto the middle band structure, theresulting outer cover is strong and reliable. Additionally, the top bandstructure and/or the bottom band structure are able to be molded using adifferent material than that used to mold the middle band structure. Forexample, as noted above, the middle band structure can be relativelyrigid, while the top band structure and/or the bottom band structure canbe relatively compliant.

Also, if there is a cut-out section (or compliant section) to beprovided within the middle band structure, then the cut-out section canalso be formed using the second moldable material. For example, the samethe injection molding step (e.g., shot) used to form of the top bandstructure and/or the bottom band structure can form the cut-out section.

The various aspects, embodiments, implementations or features of theinvention can be used separately or in any combination.

The advantages of the invention are numerous. Different embodiments orimplementations may, but need not, yield one or more of the followingadvantages. One advantage of certain embodiments of the invention isthat a cover having one or more electronic components embedded thereincan serve to extend or augment capabilities of a portable electronicdevice being covered by the cover. For example, the one or moreelectrical components provided in a cover can be used (i) to extendinput/output capabilities of the portable electronic device, (ii) toaugment functional capabilities of the portable electronic device;and/or (iii) to associate ornamental aspects to the portable electronicdevice.

The many features and advantages of the present invention are apparentfrom the written description. Further, since numerous modifications andchanges will readily occur to those skilled in the art, the inventionshould not be limited to the exact construction and operation asillustrated and described. Hence, all suitable modifications andequivalents may be resorted to as falling within the scope of theinvention.

What is claimed is:
 1. A protective cover for a portable electronicdevice, comprising: a middle ring having at least one opening for accessto an input component of the portable electronic device, the middle ringhaving a substantially flat side; a top ring integral with or attachedto a top portion of the middle ring, the top ring having a curvedcross-section; and a bottom ring integral with or attached to a bottomportion of the middle ring, the bottom ring having a curved crosssection wherein the top ring, the bottom ring, and the middle ring arealigned to secure the protective cover to a top surface and a bottomsurface of the portable electronic device and so that the substantiallyflat side of the middle ring is substantially flush with an entireperipheral surface of the portable electronic device.
 2. The protectivecover as recited in claim 1, wherein the protective cover comprises atleast one opening with a depressible actuator for use in activating auser input device of the portable electronic device while the portableelectronic device is placed within the protective cover.
 3. Theprotective cover as recited in claim 1, wherein the middle ring isformed from a plastic, and wherein the top ring and the bottom ring areformed from a thermoplastic.
 4. The protective cover as recited in claim3, wherein the thermoplastic comprises silicone.
 5. The protective coveras recited in claim 1, wherein the portable electronic device is able tobe attached to the protective cover by inserting the portable electronicdevice into the protective cover from either a top side or a bottom sideof the protective cover, and wherein the protective cover is configuredto match the configuration of the portable electronic device so that theprotective cover is removably securable thereto.
 6. A protective coveras recited in claim 5, wherein the middle ring includes an alignmentfeature configured to maintain alignment with the top ring and thebottom ring in the protective cover.
 7. A ring-shape cover having anopening configured to receive a portable electronic device, thering-shaped cover comprising: a center band primarily formed of a firstmaterial, the center band having a substantially flat side; a top bandformed of a second material and integral with a top portion of thecenter band; and a bottom band formed of the second material andintegral with a bottom portion of the center band; wherein the top band,the bottom band, and the center band are aligned to secure thering-shape cover to the portable electronic device and so that thesubstantially flat side of the center band is substantially flush withan entire peripheral surface of the portable electronic device.
 8. Thering-shaped cover as recited in claim 7, wherein each of the centerband, the top band and the bottom band surround the opening.
 9. Thering-shaped cover as recited in claim 7, wherein the ring-shaped coveris able to be attached to the portable electronic device by insertingthe portable electronic device into the opening, and wherein theportable electronic device is able to be inserted into the ring-shapedcover by way of either the bottom band or the top band.
 10. Thering-shaped cover as recited in claim 7, wherein the first material isless compliant that the second material.
 11. The ring-shaped cover asrecited in claim 7, wherein the center band include an alignment featureconfigured to maintain alignment with the top band and the bottom bandin the ring-shape cover.
 12. The ring-shaped cover as recited in claim7, wherein the center band include a compliant section that facilitatesexpansion.
 13. An edge cover for an electronic device, comprising: aremovable peripheral member that surrounds peripheral sides of anelectronic device in order to protect the peripheral sides of theelectronic device, the peripheral member having an opening extendingthrough the peripheral member and configured to receive the electronicdevice, wherein the peripheral member forms a band configured to fitaround the peripheral sides of the electronic device, and the peripheralmember comprises a substantially flat middle portion that issubstantially flush with all peripheral sides of the electronic device,the flat middle portion aligned with a curved top portion and a curvedbottom portion, the curved top portion and the curved bottom portionconfigured to secure the edge cover to a top and a bottom surface of theelectronic device.
 14. The edge cover as recited in claim 13, whereinthe removable member include a compliant section that facilitatesexpansion of the opening in the peripheral member for insertion of theelectronic device therein.
 15. An expandable edge cover for anelectronic device, comprising: a first portion in the form of a middleband having a cut out section thereby making it non-continuous, themiddle band comprising a substantially flat side; and a second portionintegrally formed with the first portion, the second portion filling thecut out section and forming a continuous upper and lower band, thesecond portion being formed from a compliant material thereby allowingthe edge cover to flex when the electronic device is inserted therein;wherein the middle band is aligned with the upper and lower band tosecure the expandable edge to a top surface and a bottom surface of theelectronic device and so that the substantially flat side of the middleband is substantially flush with an entire peripheral surface of theelectronic device.
 16. The expandable edge cover as recited in claim 15,wherein the expandable edge cover serves to cover top, bottom and leftand right sides of the electronic device.
 17. The expandable edge coveras recited in claim 15, wherein the thickness of the middle band isgreater than the thickness of the upper band or the lower band.
 18. Theexpandable edge cover as recited in claim 15, wherein the cut outsection includes an opening.
 19. The expandable edge cover as recited inclaim 15, wherein the electronic device includes a middle portion and anupper and lower portion, and wherein the middle band substantiallycorresponds to the middle portion, and the upper and lower bandssubstantially correspond to the upper and lower portions, wherein theupper and lower portions are formed from ceramics or glass.
 20. Theexpandable edge cover as recited in claim 15, wherein the upper andlower bands include a flange section configured to cover front and rearface edges of the electronic device.
 21. The expandable edge cover asrecited in claim 15, wherein the second portion is over molded relativeto the first portion.
 22. The expandable edge cover as recited in claim15, wherein the first portion is done with a first shot and the secondportion is done with a second shot in a double injection moldingoperation.